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How lean approach is utilised in the production system
Advantages and disadvantages of lean methods
The implementation of lean manufacturing focusing on
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1.0 Introduction:
In today's competitive world of manufacturing process can only be accomplished with a lean operation or with another word is called Lean Operation, is a set of tools and methodologies that aims for the continuous elimination of all waste in the production process. The main benefits of this are for getting costs of production is cheap, output will increase and production times will shorter. Lean manufacturing also can guarantee quality and maximizes efficiency. This process involves the standardization of work & eliminate waste. The standard is the best identified method of operation at a particular moment in time and one that will be continuously monitored and improvement from worker. The key to lean production is to identify processes is add value to the production process. Processes that labor and machinery can focus on added value activities’.History of Lean started with Henry Ford credited the original movement. Then follow with Kiichiro Toyoda and Taiichi Ohno: 1930’s developed the Toyota Production System (TPS) and have been implemented gradually throughout Toyota’s operations beginning in the 1950's. In 1980’s Toyota had increasingly become known for the effectiveness with which it had implemented Just-In-Time (JIT) manufacturing systems. Jim Womack, is started popular an author of Lean thinking, with a machine that can change the world and lean solutions.
Lean Manufacturing has increasingly been applied by leading manufacturing companies throughout the world, lead by the major automobile manufacturers and their equipment suppliers. Lean Manufacturing is becoming an increasingly important topic for manufacturing companies.
To implement the Standard Work is increase cost savings and maintain Lean mom...
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...ovement is at the early phases of the Lifecycle (development).
2.3 Lean Value Drivers:
• Process Waste/ Transaction Waste
• Lead time reduction (related: cycle time, TPT)
• Inventory reduction
• Cost reduction
• Environmental impact reduction (in products and or processes)
2.4 Intel A3 report
The A3 structure gives you a framework to document:
• The background and business case;
• The current condition;
• The target condition and ideal state;
• And the action plan that will close the gap between the current and target conditions.
Example of a basic A3 template you can use for a project or an initiative, structured problem solving approach prompts you to apply lean thinking and organize your thoughts before you plan your solution.
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This example shows a Strategic A3 for a project as the candidate is heading into the MEASURE Tollgate
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Achieving quality of conformance involved conform to specifications that involve providing customers with a quality product at the right price which accounts for the cost of materials. In order for a company to achieve and produce a successful product that customers want and need, it is vital that quality management and lean systems play front row. Quality management helps organizations to reduce waste and inventory. “Lean is about challenging the way things are done and opening our eyes to that waste and inefficiency” (Lean Benefits - Benefits of Lean, Why Lean is Important, 2015). Within each of these concepts are important tool and techniques that organizations can use to achieve a quality product. In this paper I will discuss “cost of quality” from the quality management side and “kaizen’s” from the lean system side, while discussing how each of these concepts are implemented into my own life or
The company that the author has chosen to compare his own organization with is the Toyota motor company. The Toyota Company has become a renowned leader in the area of quality management. Toyota’s theory of “keep it lean” has kept the company running at a level that eclipses the industry standards.
A LEAN Company is our best description and our business philosophy (creating more value for customers with less resources), which pursues to deliver what the customer wants, when they want it, at maximum value with minimum misuse.Through the application of LEAN, we achieve more fulfillment as it helps to reduce the possibility to constantly be fighting a battle against difficulties. Besides, we promote a Continuous Improvement Culture in our performance.
The production base merit and total quality management is effective approach for the organization. It kept morale high and it will continue to drive production even in a customer based work
Lean Six Sigma is a methodology that creates processes within an organization to cut waste and improve the company’s performance. However, studies have shown that over the past decade applying Lean Manufacturing and Six Sigma can create problems for companies financially and potential problems for employees. Companies should take great care before implementing a Lean Six Sigma solution because in some instances, going lean can do more harm than good both financially for the organization as well as destroying employee loyalty and moral.
Continuous improvement (CI) refers to a philosophy consisting of improvement activities that increase successes and reduce failures in a production process (Bhuiyan & Baghel 2005, p. 761). It involves activities and processes that focus on continuous and incremental innovation (Bessant et al., 1994, p.17). CI is a new approach that enhances productivity, performance, and achieves competitive advantage needed in the highly competitive industries. It may also serve as a complementary approach to other quality improvement initiatives such as total quality management (TQM) (Pike, Barnes, & Barnes 1995, p. 23; Larson 2003; Lassen, Gertsen, & Riis 2006; Oakland 2007, p. 227). The purpose of this research is to explore the application of production systems engineering methods in the CI at manufacturing plants.
The main structure of the Lockheed Martin work process consists of gathering current and future customer information, market changes and other data that influence the customer needs (Lockheed Martin, 2012). Cargill 's work process focused strongly on creating a safe work environment and community for current and future employees (Cargill Corn Milling, 2008). They chose to focus on mechanical reliability, product quality, food safety, employee safety, and the environment through a Management of Change (MOC) process and triggered by the adding of new technology to work environment. Nestle Purina focuses its work processes around technology and implementing new automated manufacturing systems. In addition, its two tier approach of constant precision and creativity (Nestle Purina, 2010). The premise is that more focus put on the output and outcome rather than rigidly followed procedures (Nestle Purina, 2010). Cargill, Nestle Purina, and Lockheed Martin, each observe the importance of finding the right fit when constructing their work processes to provide a quality or
For organizations who have committed to invest and deploy quality systems improvement programs, it is a huge task for every member who is a part of the transformation. The benefits are felt once completed and outweigh the cost from a long-term standpoint. Col. Larsen offers a compelling argument that Lean principles, when properly applied, also result in significant improvement and transcends industry boundaries. Leadership from all levels must challenge traditional approaches, communicate, and execute as a team to design and obtain excellence in governance of safety.
Once the action plan is in effect, the plan then relies on the implementation and the communication strategy for the idea to work. Communication objectives are obtained and the strategic tactics on how to communicate and disseminate the communication objectives formally and informally.
Taiwan Semiconductor Manufacturing Co. Ltd has unveiled a new and possibly controversial strategy that involves more collaboration in the early stages of the IC design process.
2. Determine where you stand vis-à-vis objectives Know where you presently stand in reaching the objectives; identify strengths that work in your favor and weaknesses that can hold you back.
Toyota is a pioneer of the LEAN manufacturing principle. Lean, as a process, is a way to add value to customers while minimizing waste (LEI, 2011). It can also be thought of in terms of flow, which is how Toyota likes to think of it. It is simply a process of decision making where the problems tend to be thought of in terms of flow, reducing starts and stops or unnecessary motion increases flow, reducing waste.
According to Koskela and Thomas et al. [4], Lean construction includes practice of just-in-time, use of pull-driven arrangement, reduction of variability in labour productivity, improvement of flow dependability, removal of waste, overview of the operation, and implementation of benchmarking.
The main idea is to fulfill the internal or external customer’s wants. Through lean thinking, it is hoping that nonmanufacturing company’s can provides value to the customers with minimum cost, effort and can save time. Thus, it will lead to improve performance and optimum utilization of the company’s additional capacity and resources.